Warp stretch fabric and method

ABSTRACT

A warp-directional stretch fabric that defines two right faces and is formed from warp yarns defined by a nylon and fill yarns defined by an aramid. The fabric can be incorporated into a toothed belt, for example a transmission belt, to produce a belt that has enhanced structural and resistance capabilities while capable of being produced at a lower cost than prior art belts. A method of producing an improved toothed belt including the fabric is also provided.

This is a continuation of and claims benefits under pending priorapplication Ser. No. 14/666,483 filed 24 Mar. 2015, now U.S. Pat.No.______issued______, which is incorporated by reference in itsentirety herein.

FIELD OF THE INVENTION

The invention herein pertains to fabrics for belts and particularlypertains to double-faced warp stretch fabric for use with transmissionbelts and the like.

DESCRIPTION OF THE PRIOR ART AND OBJECTIVES OF THE INVENTION

Toothed power transmission belts, timing belts, and serpentine belts areknown in the art and widely available commercially. These belts may beformed out of rubber and contact the drive motor shaft with one or moreteeth to transmit rotational energy for a myriad of uses, for example anautomotive alternator, power steering pump, water pump, air conditioningcompressor, air pump and the like. Due to the high environmentaltemperatures and constant stress, it is not uncommon for these belts tosuffer cracking and degradation leading to failure. One solution to thisphenomenon is to cover the inner surface of the belt, including theteeth, with a durable fabric to prevent cracking and providereinforcement and abrasion resistance during belt use. Current fabricsexhibit significant elongation or stretch in the lateral or “fill”direction, which is required for the belt building and tooth formationprocess. To accomplish effective manufacture of a covered, toothedtiming belt, a lateral width stretch fabric has to be cut and rotatedninety degrees (90°) to allow the stretch factor to be in thelongitudinal length direction to accommodate tooth formation. Therefore,there exists a need for a woven fabric with a high stretch residing inthe longitudinal or “warp” direction since belt sizes and splices in thebelts are controlled by the width of the fabric. Further, the desiredfabric has a limited porosity to prevent rubber bleed through duringtooth formation.

These belts may be formed with a woven fabric, but the weaving processcan be very expensive. Knitting the belt fabric is an efficient,low-cost option (see for example U.S. Patent Publication No.2014/0087904) which can produce a fabric demonstrating the necessaryporosity to control rubber bleed through during the belt tooth formationprocess and has to be used with the same width cover methods as otherknits. There are significant benefits to a woven fabric with highelongation in the warp direction since this would significantly reducethe cost of belt assembly and production and allow automated manufactureof belts by eliminating the cutting and turning of the fabric toposition the high stretch warp portion in the fabric in the proper planefor tooth formation. Thus, in view of the problems and disadvantagesassociated with prior art devices, the present invention was conceivedand one of its objectives is to provide a toothed belt with a reinforcedfabric covering an exterior surface with a single splice point for thefabric covering.

It is a further objective of the present invention to provide a highlydurable oil-resistant fabric that mimics the traditional surface textureof the existing width elongation fabrics positioned about the exteriorsurface of a belt.

It is another objective of the present invention to provide a satinweave for maximum blocking of fluid such as rubber by the fabricpositioned about the exterior surface of a belt while giving the samefabric wear properties of a width stretch twill constructed fabric.

It is still another objective of the present invention to provide adouble-faced fabric with a satin weave and a twill appearance.

It is yet another objective of the present invention to provide adouble-faced fabric with a broken twill construction defining a fourharness satin weave construction.

It is a further objective of the present invention to provide adouble-faced fabric formed from an aramid material and a nylon material.

It is still a further objective of the present invention to provide adouble-faced fabric formed from a relaxed nylon in the warpconfiguration and an aramid material in the fill position.

It is yet a further objective of the present invention to provide adouble-faced fabric with a material in the fill position thatexperiences less than twenty-five percent (25%) elongation whensupporting a five pound (5.0 lb) weight.

It is another objective of the present invention to provide adouble-faced fabric with a material in the warp position thatexperiences at least forty-five percent (45%) elongation when supportinga five pound (5.0 lb) weight.

Various other objectives and advantages of the present invention willbecome apparent to those skilled in the art as a more detaileddescription is set forth below.

SUMMARY OF THE INVENTION

The aforesaid and other objectives are realized by providing a toothedtransmission belt including an interior portion and at least oneexterior surface defining a plurality of rounded teeth. A woven fabricis positioned over the teeth of the exterior surface wherein the wovenfabric is a double-faced (i.e. hybrid) woven fabric with one facedefined primarily by para-aramid yarns and the other face definedprimarily by nylon yarns. The fabric is formed in a broken twill patternincluding a four harness weave configuration, producing a fabric withthe para-aramid yarns and the nylon yarns substantially exposed on oneside of the fabric or the other, allowing for targeted characteristicssuch as chemical resistance or abrasion resistance on one or both sidesof the fabric. A method of producing an improved toothed transmissionbelt as described above is also provided.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a schematic representation of a toothed belt with warpstretch fabric;

FIG. 2 pictures a perspective view of a first side of the warp stretchfabric of FIG. 1;

FIG. 3 depicts a perspective view of a second side of the warp stretchfabric of FIG. 1; and

FIG. 4 demonstrates an elevated side view of a cross-section of the warpstretch fabric of FIG. 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT AND OPERATION OF THEINVENTION

For a better understanding of the invention and its operation, turningnow to the drawings, FIG. 1 schematically illustrates toothed belt 10formed from interior or core material 11 defining at least one or moreexterior surfaces 12 including a plurality of teeth 13. Toothed belt 10is typically circular, but it should be understood that the exactmeasurements and configurations of toothed belt 10 should not beconstrued as a limitation on toothed belt 10. Embodiments of belt 10 areformed from interior materials such as rubber, polymeric derivatives,and other belt materials as are known in the art. Toothed belt 10 may beused in mechanical modes, for example in the automotive context tocontact a drive motor shaft with one or more teeth 13 to transmitrotational energy for uses such as an alternator, power steering pump,water pump, air conditioning compressor, air pump and the like (notshown). Due to the harsh operating environments of toothed belt 10, forexample when disposed as a belt-in-oil, it is not uncommon for a toothedbelt 10 to degrade over time and structurally fail. Therefore, preferredtoothed belt 10 further includes fabric 14 attached to one or moreexterior surfaces 12 and covering a plurality of teeth 13. In additionto structural protection, embodiments of fabric 14 may convey abrasionresistance properties, chemical resistance properties, stretchresistance properties, or other desirable properties.

Preferred fabric 14 is a double-faced (i.e. hybrid) woven webbing formedfrom one or more yarn types oriented in the warp (i.e. longitudinal) andfill (i.e. lateral) positions. Embodiments of fabric 14 may be formedwith warp yarns 15 and fill yarns 16 formed from the same material, butpreferred fabric 14 is formed with two “right” faces with warp yarns 15formed from a first material and fill yarns 16 formed from a secondmaterial, it being understood that the first and second materials aredifferent materials. A preferred embodiment of fabric 14 is formed fromwarp yams 15 formed from a polymeric material such as nylon 6, 6. Asecond preferred embodiment of fabric 14 is formed from fill yarns 16formed from an aramid derivative such as meta-aramid or para-aramidmaterials. Nothing in these preferred embodiments should be construed asa limitation as to the materials used to form fabric 14, and it shouldbe understood that one or more materials could be utilized as both warpyarns 15 and fill yarns 16 within the scope of the instant invention.Examples of such materials include, but are not limited to,polyamideimide (available under the tradename Kermel™), polyarylate(also known as liquid crystal polyester, available under the tradenameVectran™), polyphenlenebenzobisoxacole (available under the tradenameZylon™), polybezimdazole (available under the tradename PBI Gold™),polyphenylene sulfide (PPS), polytetrafluroethylene (PTFE),polyetheretherketone (PEEK), carbon, stainless steel, D and E glass(also known as fiberglass), basalt, and wool.

Fabric 14 may be formed from a number of different methods such asknitting, weaving, braiding, extruding, or other textile constructionmethods as are known in the art but the preferred method of formationfor fabric 14 is weaving the fabric and then attaching it to exteriorsurface 12 of toothed belt 10 as the belt is molded to define teeth 13.The weaving pattern in a woven pattern may be selected for aesthetics orvisual appearance, but the preferred pattern may also convey structureadvantages, such as enhanced structural stability or increased abrasionresistance and increased blocking of rubber from interior side of beltto flow through to the exterior surface. The weaving pattern may alsoaffect the use of the fabric, as certain patterns may form spacesbetween warp yams 15 and fill yarns 16, for example allowing some fluidssuch as air or water to pass through the fabric while restricting otherfluids such as oil or liquefied polymers and rubbers. An embodiment offabric 14 may be double-faced, in that there are two right faces of thefabric. While the faces may be completely distinct and attached throughnon-textile means, for example an adhesive, the preferred configurationof fabric 14 is referred to as a warp twill, indicating that eachrespective face is formed primarily from either warp yarns 15 or fillyarns 16. An embodiment of the warp twill defined in fabric 14 may bereferred to as a broken warp twill, a configuration that produces adiamond shape on the fabric surface. A schematic representation of sucha pattern is shown in Table 1:

TABLE 1 4 3 2 1 ⇓ X X X 1 X X X 2 X X X 3 X X X 4

Each face may be formed from a variety of stitch styles, but onepreferred stitch type defined on both faces is generally referred to asa satin weave, though having an identical weave style on both faces isnot a requirement. In addition to the weave configuration, fabric 14preferably defines a warp yarn 15 and fill yarn 16 pattern known as afour harness pattern, meaning that at respective ends of fabric 14, endsof warp yarns 15 pass above four (4) crossing fill yarns 16 beforepassing below one (1) crossing fill yarn 16 on a first face, or ends offill yarns 16 pass above four (4) crossing warp yarns 15 before passingbelow one (1) crossing warp yarn 15 on a second face. This patternproduces a first face of fabric 14 that is approximate seventy-fivepercent (75%) defined by warp yarns 15 and approximately twenty-fivepercent (25%) by fill yarns 16.

Fabric 14 can be formed on a number of weaving machines, but preferredfabric 14 is woven with a straight draw on a weaving machine configuredwith highly polished reeds, heedles, and a plurality of groups of dropwires (not shown), such as a two hundred-twenty centimeter (220 cm)Picanol Optimax Rapier™ weaving loom. The preferred total reed spread issixty-seven and two tenths of an inch (67.20″) at fifteen and an eighth(15.625) dents per inch and four (4) dents per end, with a usable reedspread of sixty-five and forty-one hundredths of an inch (65.41″)totaling one thousand fifty (1050) dents and one thousand twenty-two(1022) usable dents. This method of manufacture is capable of producingfabric 14 with a greige width of sixty-two to sixty-five inches(62.0-65.0″) and a finish width between fifty-nine and sixty-one inches(59.0-61.0″) while defining about sixty-five percent (65%) airspacewithin fabric 14 and weighing approximately four and eighty-eighthundredths ounces per square yard (4.88 oz/sq yard).

A method of producing toothed belt 10 includes the steps of providinginterior or core material 11 and molding it into a circular beltdefining at least one exterior surface 12. The method also includesweaving fabric 14, for example on a two hundred-twenty centimeter (220cm) Picanol Optimax Rapier™ weaving loom, by weaving high-stretchpolymeric warp yarns 15 formed from a nylon material such as nylon 6, 6,among fill yarns 16 formed from an aramid material such as meta-aramidor para-aramid. The weaving step may further include weaving warp yarns15 and fill yarns 16 in a satin weave, more specifically in a fourharness satin weave, and more specifically still a four harness satinweave in a broken twill pattern. This passing of warp yarn 15 over fourfill yarns 16 before passing below the next in a progressive (i.e.continuously moving the over/under pattern in successive warp ends)creates a diagonal pattern which produces the shape of a diamond on thesurface of fabric 14. By utilizing different material for warp yarns 15and fill yarns 16, these weaving steps produce a fabric with two rightfaces, capable of bestowing the resulting fabric with customizablestretch and resistance characteristics. An embodiment of fabric 14 mayalso include the weave of one or more catch-cords (not shown) formedfrom a polyester material. An alternate embodiment of fabric 14 includesa feathered edge selvage (not shown). One or more embodiments of fabric14 may undergo bulking, slitting, drying, stabilizing, coating, or otherfinishing steps after which preferred fabric 14 is then molded toexterior surface 12 of toothed belt 10 and pressure is used to formteeth 13, producing belt 10 that needs less processing time and islighter in weight than the prior art, while exhibiting stretchcharacteristics and abrasion resistance due to the nylon materialdefining warp yarns 15, chemical resistance and structural support tothe aramid material defining fill yams 16, and improved noise reductioncharacteristics resulting from the double-faced fabric 14.

The illustrations and examples provided herein are for explanatorypurposes and are not intended to limit the scope of the appended claims

I claim:
 1. A toothed belt comprising a core material defining at leastone exterior surface with a plurality of teeth, and a double-faced wovenfabric formed from a plurality of warp yarns defined by a nylon and aplurality of fill yarns defined by an aramid and attached to the atleast one exterior surface over the plurality of teeth, whereby thewoven fabric exhibits more than forty-five percent (45%) elongation inthe warp direction and less than twenty-five percent (25%) elongation inthe fill direction.
 2. The toothed belt of claim 1 whereby the corematerial is rubber.
 3. The toothed belt of claim 1 whereby the firstmaterial is nylon 6,
 6. 4. The toothed belt of claim 1 whereby thesecond material is meta-aramid.
 5. The toothed belt of claim 1 wherebythe second material is para-aramid.
 6. The toothed belt of claim 1whereby the woven fabric is a twill construction.
 7. The toothed belt ofclaim 6 whereby the woven fabric defines a broken twill pattern.
 8. Thetoothed belt of claim 7 whereby the woven fabric defines a four harnesssatin weave.
 9. A method of producing the toothed belt of claim 1, themethod comprising the steps of: providing a core material and a loomincluding warp yarns defined by a nylon material and fill yarns definedby an aramid material, molding the rubber core material into a circularbelt with at least one exterior surface, weaving the warp yarns and thefill yarns into a fabric, whereby the fabric exhibits more thanforty-five percent (45%) elongation in the warp direction and less thantwenty-five percent (25%) elongation in the fill direction attaching thedouble-faced fabric to the circular belt exterior surface, and moldingthe circular belt to define a plurality of teeth.
 10. The method ofclaim 9, whereby weaving the warp and fill yarns further comprisesweaving the double-faced fabric via a four harness satin weave in abroken twill pattern.
 11. The method of claim 9 whereby the nylonmaterial is nylon 6,
 6. 12. The method of claim 9 whereby the aramidmaterial is meta-aramid.
 13. The method of claim 9 whereby the aramidmaterial is para-aramid.